Method of forming a capacitor assembly in a circuit board

ABSTRACT

A circuit board includes an assembly having first and second power reference plane layers, and an insulator layer between the first and second power reference plane layers. Discrete decoupling capacitors are further provided with the assembly. Additional layers are provided above and below the assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from and is a divisional patentapplication of U.S. patent application Ser. No. 10/287,116, filed Nov.4, 2002, now U.S. Pat. No. 6,844,505.

BACKGROUND

A circuit board (sometimes referred to as a printed circuit board or aprinted wiring board) is the basic building block for interconnectingelectronic devices in a system. Electronic devices, usually integratedcircuit (IC) devices, are mounted onto the circuit boards using a numberof mounting mechanisms, such as by use of connectors or by directlymounting the devices onto a surface of the circuit board. A circuitboard also includes the wiring required to interconnect the deviceselectrically.

The number and density of signal lines in a circuit board arecontinuously increasing due to the increased density of circuits thatcan be formed on each IC chip. The number of input/output (I/O) pinsthat exist on each IC chip can be quite large, which means that a largenumber of signal wires are needed to carry signals from one IC chip toanother component in the system. To increase the density of signal wiresthat can be provided in the circuit board, a circuit board is usuallyformed of multiple layers. Some layers contain signal wires fortransmitting signals, while other layers contain power reference planes,which are connected to ground or to a power supply voltage, e.g., athree-volt voltage, a five-volt voltage, or some other power supplyvoltage. In other arrangements of circuit boards, power reference planesare not used. To connect signal wires in different layers of the circuitboard, vias are provided. A via is an electrical connection that is runthrough multiple layers of the circuit board to complete a signal pathusing different layers, or to provide an electrical connection to groundor power. Typically, the via is run generally perpendicularly to a mainsurface of the circuit board.

With large numbers of IC chips and signal wires (I/O circuits) in acircuit board, switching noise can be a problem during system operation,especially at high frequencies. To mitigate switching noise, surfacemount technology (SMT) decoupling capacitors are commonly used. Thesecapacitors are mounted to either the primary or secondary (top orbottom) surface of the circuit board, and connected to reference planesthrough vias. At high frequencies, a capacitor provides a low impedancebypass path for switching noise between the power supply voltage planeand the ground plane.

One issue associated with connecting decoupling capacitors to referenceplanes is the relatively high inductance resulting from the combinationof the capacitor's package, a via, and the interconnecting structurefrom the decoupling capacitor to the via. As frequencies increase intothe hundreds of megahertz (MHz) or gigahertz (GHz) range, the impedanceassociated with the combined inductance of each decoupling capacitorcircuit becomes much larger than the capacitive impedance associatedwith the decoupling capacitor itself. To reduce the package inductance,surface mount technology (SMT) capacitors are used. To reduce theinterconnection inductance, low-inductance interconnections are used,such as short wires, wide interconnects, multiple vias, and so forth.Nevertheless, because of the increased impedance caused by theinductance of the via, the SMT decoupling capacitor is unable toeffectively provide a low-impedance bypass path for switching noise athigh frequencies. In other words, because of a significant impedanceintroduced by the via inductance into the decoupling path, a capacitorloses its decoupling effectiveness in providing a bypass path for highfrequency noise.

Other techniques have also been employed to provide decouplingcapacitance in circuit boards. For example, an embedded capacitance in acircuit board has been employed to avoid effects of via inductances.However, conventional embedded capacitance techniques are typicallyassociated with relatively low capacitance, which means increasedimpedance at high frequencies. Without effective decoupling, switchingnoise on a circuit board can cause device operation to fail undercertain conditions.

SUMMARY

In general, enhanced mounting techniques and mechanisms for decouplingcapacitors are provided in a circuit board to improve decouplingcharacteristics. For example, a circuit board includes a core assemblyhaving first and second power reference plane layers, an insulator layerbetween the power reference plane layers, and discrete capacitors eachabutting one of the first and second power reference plane layers.Additional layers are provided above and below the core assembly.

Other or alternative features will become more apparent from thefollowing description, from the drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example arrangement of a circuit board thatincludes buried, discrete decoupling capacitors.

FIG. 2 illustrates openings formed through a dielectric layer, inaccordance with an embodiment.

FIG. 3 is a flow diagram of a process according to one embodiment ofbuilding a core assembly for use in the circuit board of FIG. 1.

FIG. 4 is a cross-sectional view of a core assembly according to oneembodiment for use in the circuit board of FIG. 1.

FIG. 5A is a flow diagram of a process according to another embodimentof building a core assembly for use in the circuit board.

FIGS. 5B–5D illustrate various arrangements to enhance contact printsbetween a decoupling capacitor and power reference plane layers.

FIGS. 6 and 7 illustrate side views of layers in a circuit boardaccording to two embodiments.

FIG. 8 illustrates a side view of a core assembly according to anotherembodiment.

FIG. 9A is a top view of a portion of the core assembly of FIG. 8.

FIG. 9B is a side view of another embodiment.

FIG. 10 illustrates a side view of a circuit board that includes thecore assembly of FIG. 8.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to providean understanding of the present invention. However, it will beunderstood by those skilled in the art that the present invention may bepracticed without these details and that numerous variations ormodifications from the described embodiments are possible.

As shown in FIG. 1, an example circuit board 100 includes multiplelayers 102, 104, 106, 108, 112, 114, 116, and 118. In other embodiments,a larger or smaller number of layers can be used in the circuit board.As used here, a “circuit board” refers to any structure containingsignal wires or conductors (for routing signals) and containing powerreference planes (to carry ground and power supply voltages). Examplesof a “circuit board” include printed wiring boards (PWBs) and printedcircuit boards (PCBs). A “circuit board” also covers any package, suchas an integrated circuit (IC) package, that has multiple layers ofsignal wires or conductors and power reference planes. The circuit board100 is part of a system that includes various components, such as a harddisk drive, a display, a central processing unit (CPU), a power supply101, and so forth. The components (e.g., devices 130) are mounted on onesurface (or both a top and bottom surface) of the circuit board 100.

In the example shown in FIG. 1, the layers 102, 106, 114, and 118 aresignal layers for carrying signal wires, while the layers 104, 108, 112,and 116 are power reference plane layers that contain either a groundplane or a power supply voltage plane connected to a power supplyvoltage, (e.g., 3 volts, 5 volts, 12 volts, etc.) produced by the powersupply 101. Dielectric layers 140, 142, 144, 110, 146, 148, and 150 areprovided between successive signal and/or reference plane layers. Thedielectric layers are insulator layers to isolate electrical conductorsin the circuit board.

The dielectric layer 110 contains multiple decoupling capacitors toprovide a bypass path for switching noise between a power supply voltageplane and ground plane. Thus, in the example of FIG. 1, one of thereference layers 108 and 112 is a ground reference layer, while theother one of the reference layers 108 and 112 is a power supply voltagereference layer. The decoupling capacitors in the dielectric layer 110each has electrodes that are electrically coupled to the power referencelayers 108 and 112.

Although only one assembly of the dielectric layer 110 with embeddeddecoupling capacitors is shown in FIG. 1, other embodiments may utilizeadditional such layers with embedded decoupling capacitors. For example,to be more effective, the assembly of the dielectric layer 110 withembedded capacitors is placed close to active devices mounted on oneside of the circuit board. Another assembly of a dielectric layer withembedded capacitors is placed close to active devices on the other sideof the circuit board.

Further, as shown in FIG. 1, devices 130 are mounted on a planar surfaceof the circuit board 100. Signal traces 120 in the layer 102 routesignals from the devices 130 to other points on the circuit board 100.Some of the signal traces 120 connect input/output (I/O) pins of thedevices 130 to via pads 122 and 124. The via pads 122 and 124 are inturn connected to vias 126 and 128, respectively, which are passedgenerally vertically through the multiple layers of the circuit board100.

Although vias are used to connect signal wires, such vias (which haveassociated inductances) are not used to connect decoupling capacitorsbetween power reference planes. Instead, buried discrete capacitors inthe dielectric layer 110 are electrically contacted to the referenceplanes 108 and 112 to provide low impedance bypass paths (at highfrequencies) for switching noise. In accordance with some embodiments ofthe invention, the electrical contact between electrodes of the buriedcapacitors and the reference plane layers are associated with much lowerinductances than inductances of standard vias used to connect the signalwires. In some embodiments, the electrical contact between thedecoupling capacitors and the reference planes 108 and 112 isimplemented with micro-vias, which are very small vias of short lengthsto electrically contact one electrical component to another electricalcomponent. Due to their much shorter length, micro-vias have muchsmaller inductances than standard vias. In other embodiments, othertypes of low-inductance electrical contact can be used for electricallycontacting the buried decoupling capacitors in the layer 110 to thereference plane layers 108 and 112. The low inductance of the electricalcontact between the capacitor electrodes and the power reference planesallows provision of the low impedance bypass path through the decouplingcapacitors for high-frequency noise.

FIG. 2 shows a top view of the dielectric layer 110. The dielectriclayer 110 has a top planar surface 200. Although not shown in FIG. 2,the dielectric layer 110 also has a bottom planar surface, which is onthe opposite side of the dielectric layer 110 from the top surface 200.A plurality of openings 210 are formed through the dielectric layer 110.The openings (or holes) are formed to extend from the top or mainsurface 200 of the dielectric layer to the bottom surface of thedielectric layer such that the opening passes through the entirethickness of the dielectric layer 110. In the embodiment shown in FIG.2, each opening runs along a direction that is generally perpendicularto the top surface 200 of the dielectric layer 110. Although shown asbeing generally rectangular or square in shape, the openings 210 canhave other of shapes, such as circular, oval, triangular, and so forth.Discrete decoupling capacitors 212 are provided in the openings 210.

The discrete openings 210 in the dielectric layer 110 enable theprovision of discrete capacitors 212 in the layer 110. In oneembodiment, the type of discrete capacitors used is of the surface mounttechnology (SMT) type. As used here, SMT refers to the type of capacitorused, not to the mounting mechanism of the capacitor. In fact, the SMTcapacitors 212 are buried within an inner layer of the circuit board andnot mounted to an external surface of the circuit board. A benefit ofusing SMT capacitors is that they can be “off-the-shelf” discrete ICcomponents that are easily available. Each of such off-the-shelfcapacitors has an outer package or protective housing to surround thecapacitor components. Electrodes protrude from the package to enableconnection of each discrete capacitor to other components. In otherembodiments, other types of discrete capacitors are used (e.g., round orcircular capacitors). The term “discrete capacitors” generally refers tocapacitors that have separate electrodes and dielectric layers—in otherwords, two capacitors are discrete if they do not share any of theirelectrodes and dielectric layer with another capacitor.

In yet other embodiments, the discrete capacitors are formed bydepositing electrode layers and the capacitor dielectric layer in eachopening 210 of the layer 110.

FIG. 3 shows a process according to an embodiment for building a coreassembly that includes the dielectric layer 110 with openings in whichare fitted decoupling capacitors. The core assembly also includeselectrically conductive foils 220 and 222 (FIG. 4) on both sides of thedielectric layer 110. As examples, the electrically conductive foils 220and 222 are copper or other electrically conductive foils. According tothe process of FIG. 3, openings or holes have previously been punched,drilled, or otherwise formed in the dielectric layer (at 302). Thebottom electrically conductive foil 220 is placed (at 303) overregistration pins, which are structures used to align the multiplelayers that make up the assembly. Next, the dielectric layer 110 isplaced (at 304) over the bottom electrically conductive foil using thesame or a different registration mechanism.

Next, the discrete capacitors 212 are placed (at 306) in the openings210 of the dielectric layer 110. The top electrically conductive foil222 is then placed (at 308) on the top surface 200 of the dielectriclayer 110 such that the top electrically conductive foil 222 abuts orcontacts the top surface 200 of the dielectric layer 110. A registrationmechanism is also used to properly locate the top conductive foil withrespect to the remainder of the assembly. Note that the top and bottomfoils 222 and 220 are separate from the electrodes of the capacitor. Infact, the foils 220 and 222 make up the power reference planes.

The core assembly of the dielectric layer 110, top and bottomelectrically conductive foils 220 and 222, and capacitors 212 is thenheated (at 310) to slightly above reflow temperature (of the dielectricmaterial in the layer 110). This causes the dielectric material in thelayer 110 to flow and bond to the electrically conductive foils 220 and222. While the core assembly is heated, pressure is applied to the topand bottom foils 220 and 222 to form the bond between the foils 220 and222 and the respective surfaces of the dielectric layer 110. To form theelectrical contact between each foil 220 and 222 and respectiveelectrodes 224 and 226 of the capacitors 212, micro-vias 230 and 232 aredrilled or otherwise formed (at 312) in both the top and bottomelectrically conductive foils 220 aid 222. After the micro-vias aredrilled, the micro-vias are plated (at 314) to electrically contact thecapacitor electrodes 224 and 226 to the foils 220 and 222, respectively.

After the process performed in FIG. 3, a core assembly has been builtthat contains the dielectric layer with buried, discrete decouplingcapacitors and top and bottom electrically conductive foils that can beelectrically connected to power reference planes (a ground referenceplane and a power supply voltage reference plane) of a circuit board,such as the circuit board 100 shown in FIG. 1. In some circuit boards,only one core assembly per circuit board is needed. In other cases,multiple core assemblies can be implemented into a circuit board.

FIG. 5A shows another embodiment of forming the core assembly. In thisother embodiment, the decoupling capacitors 212 are soldered (at 402) tothe bottom electrically conductive foil 220 at specified locations.Next, openings are punched or drilled (at 404) in the dielectric layer110 at locations corresponding to the capacitor locations on the bottomelectrically conductive foil 220. The dielectric layer 110, with theopenings 210 formed therein, is then placed (at 406) over the capacitorsthat are soldered to the bottom electrically conductive foil 220. Next,the top electrically conductive foil 222 is placed (at 408) over thedielectric layer. The assembly is then heated (at 410) to slightly abovereflow temperature while pressure is applied. Micro-vias are thendrilled (at 412) into the top electrically conductive foil 222 at thecapacitor locations. The micro-vias are then plated (at 414) toelectrically contact the top electrically conductive foil 222 to theelectrodes 226 of corresponding capacitors 212.

In yet another process according to a different embodiment, holes oropenings are first punched or drilled into the dielectric layer 110 atcapacitor locations. Then, the bottom electrically conductive foil 220is placed under the dielectric layer 110, with capacitors placed intothe openings 210 of the dielectric layer 110. Next, the top electricallyconductive foil 222 is placed onto the top surface of the dielectriclayer 110. The whole assembly is then heated to slightly above reflowtemperature while pressure is applied. In this different embodiment,electrical contact of the foils 220 and 222 to electrodes of thecapacitor 212 is maintained by compression. The compression ismaintained by the board lamination process of “gluing” or bonding thedielectric layer 110 to the electric foils 220 and 222 by the reflow ofthe dielectric material under pressure. The printed circuit boardmanufacturing process eliminates air and other gases that may be presentor may have been introduced to the core assembly that would reduce theeffectiveness of the compression electrical contact between the foilsand capacitor electrodes.

In the embodiment in which electrical contact between the foils and thecapacitor electrodes are maintained by compression, the electricalcontact is enhanced by forming irregular contact surfaces to provide aroughened profile. As shown in FIG. 5B, a capacitor 430 has a firstelectrode 432 and a second electrode 434. The upper surface 436 of theelectrode 432 is formed to have an irregular pattern so that high pointsare provided to provide high-pressure points when an upper electricallyconductive foil 440 is contacted to the electrode surface 436.Similarly, a lower surface 438 of the electrode 434 is formed to have anirregular pattern to provide better electrical contact points with alower electrically conductive foil.

In one arrangement, as shown in FIG. 5C, a pattern 450 is formed on theupper surface 436 of the electrode 432. A similar pattern (not shown) isformed on the lower surface. The pattern 450 is formed by scoring,etching, or by some other suitable techniques. One example etchingtechnique involves placing a mask with predefined openings in the maskto allow desired portions of the electrode surface 436 to be etched by achemical agent, by plasma, or by some other agent. Alternatively, adendritic plating technique is employed to form the pattern 450 on theelectrode surface 436. In yet another alternative technique, mechanicalinterruption is employed to form the pattern 450, such as with use of acutter or the like to cut the pattern 450 into the surface 436.

As shown in FIG. 5D, in another arrangement, bumps 452 are formed on theelectrode surface 436. A “bump” refers to any raised structure thatprotrudes from the general surface of the electrode 432. The bumps 452are deposited onto or otherwise formed on the electrode surface 436.

In other embodiments, other techniques can also be used to roughen thecontact surface of a capacitor electrode. For example, such othertechniques can be similar to techniques used by manufacturers to roughenan outside surface of a power reference plane foil.

FIG. 6 shows an example arrangement of a multi-layered circuit boardthat incorporates the core assembly made according to any one of theprocesses discussed above. The circuit board arrangement 500 of FIG. 6includes the core assembly 502, which has multiple buried, discretedecoupling capacitors placed in corresponding openings 210 of thedielectric layer 110. One electrically conductive foil 504 iselectrically connected to a power supply voltage reference plane, whileanother electrically conductive foil 506 of the core assembly 502 iselectrically connected to a ground reference. In building up the circuitboard 500, additional dielectric layers 508 and 510 (referred to asprepreg layers) are provided on the two sides of the core assembly 502).A prepreg layer is an insulator layer that contains a material designedto meet at a predetermined temperature. For example, the prepreg layerincludes gas fibers pre-impregnated with epoxy, with the epoxyformulated to melt into liquid form at a predetermined temperature. Acore assembly 511 is placed above the prepreg layer 508. The coreassembly 511 differs from the core assembly 502 by not including burieddecoupling capacitors. The core assembly 511 has a dielectric layer 512and two electrically conductive foils 514 and 516 provided on the twosides of the dielectric layer 512. In the example arrangement shown inFIG. 6, the electrically conductive foil 514 is connected to a groundreference, and the electrically conductive foil 516 is patterned into alayer of signal wires. A similar core assembly 518 is provided below theprepreg layer 510. Additional prepreg layers and core assemblies arefurther added to the assembly to form the multi-layered circuit board500.

The embodiments discussed above utilize core assemblies each withdecoupling capacitors in a dielectric layer along with electricallyconductive foils on the two sides of the dielectric layer. In anotherembodiment, instead of one of the core assemblies discussed above, thediscrete decoupling capacitors are provided in a prepreg dielectriclayer or any other type of insulator layer (which does not include theelectrically conductive foils on the two main surfaces of the insulatorlayer). As shown in FIG. 7, a multi-layered circuit board 600 includesthe modified prepreg layer 602 that has the dielectric layer along withburied decoupling capacitors 608 placed in openings of the dielectriclayer. In this alternative embodiment, a first circuit board 604 and asecond circuit board 606 are built in a conventional manner. Thesecircuit boards 604 and 608 are then abutted to the two main surfaces ofthe prepreg layer 602 with the buried capacitors 608. The upper circuitboard 604 is placed on one main surface of the prepreg layer 602, whilethe second circuit board 606 is placed on the other main surface of theprepreg layer 602. After the circuit boards are placed on the two mainsurfaces of the prepreg layer 602, the whole circuit board 600 is heatedto slightly above reflow temperature while pressure is applied to reflowthe dielectric of the prepreg layer 602 to bond the prepreg layer 602 tothe respective surfaces of the circuit boards 604 and 606. Electricalcontact of the power supply voltage reference plane layer 610 and theground reference plane layer 612 to the electrodes of the capacitor 608is maintained by compression.

In the various embodiments, discrete, buried decoupling capacitors areprovided in openings of a dielectric layer. The benefit offered by suchdiscrete capacitors is that the overall capacitance provided by suchcapacitors is relatively large. The positions of the buried decouplingcapacitors according to the various embodiments avoid the introductionof relatively large inductances (such as inductances associated withstandard vias) into electrical paths of connections between electrodesof the decoupling capacitors and a power reference plane, with therelatively large inductances reducing the overall effectiveness of thedecoupling capacitors. The larger capacitance offered by the decouplingcapacitors over some conventional techniques allows for more effectiveremoval of switching noise, especially at high frequencies.

In yet another embodiment, a different arrangement uses a core assemblyin which the buried discrete capacitors are placed not between the powersupply voltage plane layer and the ground plane layer, but on outersurfaces of the power supply voltage and ground plane layers. Such anarrangement is shown in FIG. 8, which shows a core assembly 700 thatincludes power reference plane layers 702 and 704 that are separated bya dielectric layer 706.

In addition, the core assembly 700 includes discrete surface mountcapacitors 708 that are placed on the outer surface 710 of the powerreference plane layer 702, and discrete capacitors 714 that are placedon the outer surface 716 of the power reference plane layer 704. Eachcapacitor 708 has electrodes 720 and 724, with electrode 720electrically connected to the power reference plane layer 702 (e.g., bysoldering, wiring, etc.). The other electrode 724 is electricallyconnected to a via 726 that extends through a via hole 728 through thelayers 702, 706, and 704 that are part of the core assembly 700.

Each capacitor 714 also has electrodes 730 and 732, with electrode 730electrically connected to the power reference plane layer 704. The otherelectrode 732 is electrically connected to a via 726.

As discussed above, one electrode of each of the capacitors shown inFIG. 8 is electrically connected to the surface of the power referenceplane layer on which the capacitor is mounted. However, the otherelectrode of the capacitor is insulated from, and thus is notelectrically connected to, the surface on which the capacitor ismounted. As shown in the top view of FIG. 9A, the electrode 720 of thecapacitor 708 is electrically connected (e.g., soldered) to the topsurface 710 of the power reference plane layer 702. However, the otherelectrode 724 of the capacitor 708 is provided in an anti-pad (orclearance) region 740 defined in the power reference plane layer 702. Asa result, the electrode 724 is electrically isolated from the powerreference plane layer 702.

A pad 742 is defined to provide a region at which the capacitorelectrode is to contact the via. The clearance 740 is defined around thepad 742.

In a different arrangement, as shown in FIG. 9B, a pad does not need tobe defined. A clearance (anti-pad) 750 is defined in the power referenceplane layer 702. A hole or void 754 is punched, or drilled, or otherwiseformed through the power reference plane layer 702 and the dielectriclayer 706. The capacitor 708 is placed such that its electrode 724 isprovided over the hole or void 754. The other electrode 720 of thecapacitor 708 is soldered at 752 to the upper surface 710 of the powerreference plane layer 702.

The circuit is completed when an electrically conductive material, suchas electrically conductive epoxy or some other material, is provided tofill the hole or void 754 so that a electrical connection is providedbetween the capacitor electrode 724 and the power reference plane layer704. The electrically conductive material forms a via 756.

Note that the hole or void 754 is formed to have a relatively largecross-sectional area (larger than the cross-sectional area of otherplated hole vias in the circuit board). As a result, the via 756 has alower inductance than such other vias. If a punching technique is usedto form the hole 754, such a punching technique allows the formation ofa hole that is not limited to a circular cross-sectional profile (aswould be the case with drilling). Also, punching avoids the need forsecondary fabrication steps such as de-burring and plating.

If electrically conductive epoxy or other like material is used to formthe via 756, such material is associated with a higher resistance thanthat offered by a plated via. The increased resistance aids inhigh-frequency noise mitigation. The overall conductivity (and hence theresistivity) of the epoxy can be tailored by adjusting the percentage ofelectrically conductive particles mixed into the epoxy.

In the arrangement of FIGS. 8 and 9, vias 726 that extend through twoconductive layers and one dielectric layer are employed to electricallyconnect discrete capacitors 708 and 714 between two power referenceplane layers. The vias 726 extend through a relatively small number oflayers (or just a dielectric layer) and thus are of relatively shortlength. Therefore, the vias 726 are associated with relatively smallinductances so that the capacitors 708 and 714 are able to provideeffective bypass paths for high-frequency switching noise. Eachcapacitor 708 and 714 only requires via 726 at one electrode of thecapacitor, thus maintaining relatively small inductances to provideeffective bypass paths for high frequency switching noise.

A benefit offered by the arrangement of FIG. 8 is that the powerreference plane layers 702 and 704 (one containing a power supplyvoltage plane and the other containing a ground plane) can be moreclosely spaced than in some of the arrangements shown in FIGS. 2, 4, 6,and 7. In those arrangements, discrete capacitors are placed between thepower reference plane layers 702 and 704 so that a separation betweenthe power reference plane layers equal to or slightly larger than thethickness of the discrete capacitors is needed. However, with thearrangement of FIG. 8, the discrete capacitors are moved from betweenthe power reference plane layers of the core assembly 700 to the outersurfaces of the power reference plane layers. As a result, theseparation (indicated by height “h” in FIG. 8) between the powerreference plane layers 702 and 704 can be reduced, particularly ascompared to the embodiments of FIGS. 2, 4, 6, and 7 that use relativelylarge (associated with a large height) discrete capacitors. Placing thepower reference plane layers 702 and 704 closer together also helps inreducing effects of switching noise.

As examples, the height h, representing the separation between the powerreference plane layers 702 and 704, is made to be less than or equal to20 mils. In fact, for even better noise performance, the height h isfurther reduced to less than or equal to 10 mils, 5 mils, or 2 mils.

For the embodiments of FIGS. 2, 4, 6, and 7, the separation of the powerreference plane layers that embed the discrete capacitors can be reducedif discrete capacitors of smaller sizes are used.

In the embodiment of FIG. 8, a smaller height h adds a further benefit:the inductance of the via 726 is reduced so that the series inductancein the bypass path that also includes a decoupling capacitor is alsoreduced.

FIG. 10 shows the core assembly 700 of FIG. 8 embedded between otherlayers of a circuit board 800. In the example arrangement of FIG. 10,the circuit board 800 also includes core assemblies 814 and 816 (withoutdiscrete capacitors) on the two sides of the core assembly 700. The coreassembly 814 includes a signal layer 804, a power reference plane layer810, and a dielectric material 818 between layers 804 and 810.Similarly, the core assembly 816 includes a signal layer 806, a powerreference layer 812, and a dielectric layer 820. Other layers of thecircuit board 800 include signal layers 802 and 808 and prepreg layers822, 824, 826, and 828.

If the discrete capacitors 708 and 714 are relatively large, then theymay cause high-pressure regions to develop in the abutting prepreglayers 824 and 826 during circuit board fabrication. To alleviate this,depressions or grooves 830 are formed in the surface of the prepreglayer 824 abutting the capacitors 708. The depressions or grooves 830are formed at locations of the capacitors 708 so that the depressions orgrooves 830 receive the capacitors 708 when the prepreg layer 824 isplaced over the core assembly 700. Similarly, depressions or grooves 832are formed in the surface of the prepreg layer 826 abutting thecapacitors 714 at the locations of the capacitors 714.

While the invention has been disclosed with respect to a limited numberof embodiments, those skilled in the art will appreciate numerousmodifications and variations therefrom. It is intended that the appendedclaims cover such modifications and variations as fall within the truespirit and scope of the invention.

1. A method of forming an assembly for use in a circuit board,comprising: providing a dielectric layer; forming plural openings in thedielectric layer; placing discrete capacitors in the plural openings;forming a roughened profile on each electrode of each capacitor;abutting a first and a second power reference layers to the respectivesurfaces of the dielectric layer; electrically connecting the first andthe second power reference layers to the respective electrodes of thecapacitors by contacting the roughened profile of each electrode to therespective power reference layers; and compressing the first and thesecond power reference layers to the respective surfaces of thedielectric layer to maintain electrical contact between the first andthe second power reference layers and the capacitors.
 2. The method ofclaim 1, wherein forming the roughened profile comprises performing oneof scoring, etching, and dendritic plating.
 3. The method of claim 1,wherein forming the roughened profile comprises forming bumps on asurface of each electrode.